WO1994025304A1 - Power collector for inductive power transfer - Google Patents

Power collector for inductive power transfer Download PDF

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Publication number
WO1994025304A1
WO1994025304A1 PCT/NZ1993/000030 NZ9300030W WO9425304A1 WO 1994025304 A1 WO1994025304 A1 WO 1994025304A1 NZ 9300030 W NZ9300030 W NZ 9300030W WO 9425304 A1 WO9425304 A1 WO 9425304A1
Authority
WO
WIPO (PCT)
Prior art keywords
power
primary
coil
inductive
power collector
Prior art date
Application number
PCT/NZ1993/000030
Other languages
French (fr)
Inventor
Peter Bruce Clark
Original Assignee
Cadac Holdings Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Cadac Holdings Limited filed Critical Cadac Holdings Limited
Priority to PCT/NZ1993/000030 priority Critical patent/WO1994025304A1/en
Priority to US08/545,723 priority patent/US5839554A/en
Priority to AU40933/93A priority patent/AU4093393A/en
Publication of WO1994025304A1 publication Critical patent/WO1994025304A1/en

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60LPROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L5/00Current collectors for power supply lines of electrically-propelled vehicles
    • B60L5/005Current collectors for power supply lines of electrically-propelled vehicles without mechanical contact between the collector and the power supply line
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60LPROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L50/00Electric propulsion with power supplied within the vehicle
    • B60L50/50Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells
    • B60L50/53Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells in combination with an external power supply, e.g. from overhead contact lines
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60LPROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L50/00Electric propulsion with power supplied within the vehicle
    • B60L50/50Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells
    • B60L50/60Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells using power supplied by batteries
    • B60L50/66Arrangements of batteries
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60LPROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L53/00Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
    • B60L53/10Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles characterised by the energy transfer between the charging station and the vehicle
    • B60L53/12Inductive energy transfer
    • B60L53/124Detection or removal of foreign bodies
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60LPROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L53/00Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
    • B60L53/10Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles characterised by the energy transfer between the charging station and the vehicle
    • B60L53/12Inductive energy transfer
    • B60L53/126Methods for pairing a vehicle and a charging station, e.g. establishing a one-to-one relation between a wireless power transmitter and a wireless power receiver
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F38/00Adaptations of transformers or inductances for specific applications or functions
    • H01F38/14Inductive couplings
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60LPROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2200/00Type of vehicles
    • B60L2200/18Buses
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60LPROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2200/00Type of vehicles
    • B60L2200/26Rail vehicles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60LPROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2210/00Converter types
    • B60L2210/10DC to DC converters
    • B60L2210/12Buck converters
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60LPROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2210/00Converter types
    • B60L2210/30AC to DC converters
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60LPROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2220/00Electrical machine types; Structures or applications thereof
    • B60L2220/10Electrical machine types
    • B60L2220/16DC brushless machines
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60LPROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2240/00Control parameters of input or output; Target parameters
    • B60L2240/40Drive Train control parameters
    • B60L2240/42Drive Train control parameters related to electric machines
    • B60L2240/421Speed
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00Road transport of goods or passengers
    • Y02T10/60Other road transportation technologies with climate change mitigation effect
    • Y02T10/64Electric machine technologies in electromobility
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00Road transport of goods or passengers
    • Y02T10/60Other road transportation technologies with climate change mitigation effect
    • Y02T10/70Energy storage systems for electromobility, e.g. batteries
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00Road transport of goods or passengers
    • Y02T10/60Other road transportation technologies with climate change mitigation effect
    • Y02T10/7072Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00Road transport of goods or passengers
    • Y02T10/60Other road transportation technologies with climate change mitigation effect
    • Y02T10/72Electric energy management in electromobility
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T90/00Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02T90/10Technologies relating to charging of electric vehicles
    • Y02T90/12Electric charging stations
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T90/00Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02T90/10Technologies relating to charging of electric vehicles
    • Y02T90/14Plug-in electric vehicles

Definitions

  • This invention relates to a system for inductive transfer of power across a gap, useful in the provision of electric power to one or more mobile consumers of electric power. It has particular application to an electrically powered railway or to road vehicles.
  • inductive coupling as a roadway power transmission system has been known for approximately 100 years, and there have been many attempts to develop the use of inductive coupling for the transportation of road vehicles. However, they have not proved to be sufficiently efficient and hence not commercially successful.
  • the invention comprises a power collector for collecting power from an inductive power transfer system across a space, using as its primary emitters of power as varying magnetic flux one or more primary conductors capable of carrying an alternating electric current having an operating frequency, the power collector comprising at least one capacitance and at least one coil of one or more windings for intercepting the magnetic field from the one or more primary conductors, and at least one electrical load, characterised in that the capacitance is in series with the coil and the load, and the reactance of the series capacitance is substantially equal to the inductive reactance of the coil at the operating frequency.
  • the windings of the coil of the power collector are made of solid conductive metallic material.
  • the electrical load comprises a device capable of immediately consuming the alternating current developed within the windings of the coil.
  • the electrical load comprises a device capable of using power from a storage battery connected to the power collector.
  • the load comprises a device capable of using the alternating current after a first conversion into direct current and a second conversion into a voltage or current of a regulated amplitude.
  • the load comprises a DC motor capable of providing a motive power.
  • the invention comprises a primary conductor (for use with a power collector), comprising an elongated loop formed from one or more turns of an insulated conductive cable of a type having, for the conductive portion, a low ratio of external surface area to volume.
  • the conductive cable may optionally comprise a superconductive material of a type capable of exhibiting a very low ohmic resistance when cooled to below its superconducting temperature.
  • the invention provides an inductive power transfer system in combination with a power collector as previously described, said system comprising a source of alternating electric power having an operating frequency; a resonant primary; a vehicle having at least one said power collector mounted thereon; wherein said power collector comprises at least one capacitance and at least one coil of one or more windings for intercepting the magnetic field from the one or more primary conductors, and at least one electrical load, characterised in that the capacitance is in series with the coil and the load, and the reactance of the series capacitance is substantially equal to the inductive reactance of the coil at the operating frequency.
  • At least one metallic rail may be used as a primary conductor, upon which a substantially non-conductive vehicle may be supported by at least one non- conductive support incapable of conducting an electric current from the rail.
  • the operating frequency of the source of alternating power used in this system lies in the range of from 30 Hz to 1 MHz.
  • the operating frequency of the source of alternating power is that of a local mains supply frequency or an integer multiple of the supply frequency.
  • each loop being contiguous at at least one end with an adjacent loop.
  • one or more physically separated primary loops are located at designated positions.
  • the invention may comprise a self-powered vehicle, adapted for use with an inductive power transfer system, comprising at least three road wheels and means for control and guidance, at least one power collector, apparatus for conversion of electrical energy into a storable form, apparatus for storage of electrical energy, and apparatus for recovery of stored electrical energy and its controlled delivery to at least one electromotive transducer.
  • FIG. 1 is a schematic diagram of an inductively coupled railway with series capacitor.
  • FIG. 2 illustrates a cross-section through a pair of rails, and through an electrically powered trolley positioned on said rails.
  • FIG. 3 is a top plan view of a coil positioned above said pair of rails.
  • FIG. 4 illustrates a simple resonant circuit to illustrate the power pick-up in the coil of the vehicle.
  • FIG. 5 illustrates a series resonant circuit for use in the coil of this invention.
  • FIG. 6a illustrates a vehicle with on-board storage at a designated charging place.
  • FIG. 6b illustrates a preferred primary conductor loop.
  • FIG. 6c illustrates a superconducting primary conductor loop.
  • FIG. 7a illustrates a vehicle at a designated charging place, illustrating the relationship of the primary windings and the power collector.
  • FIG. 7b illustrates a section through a power collector.
  • Alternating current is supplied to a pair of parallel conductors (in this case a pair of electrically conductive rails 11).
  • the frequency may vary from about 50 Hertz (50 Hz) to several MegaHertz (MHz) depending upon the size and nature of the track and trolley, and the relative economics of high frequency generation over frequencies related to mains frequencies.
  • the power is supplied at a frequency in the range of 2 KiloHertz (KHz) to 20
  • the frequency and the current developed by the power supply may be selected, or varied, depending upon the size and nature of the rails, the size and nature of the pick-up coil, and the power requirements of the electric motor or motors on each trolley.
  • the induction system of this invention is particularly suited to an electrical railway in which a pair of electrically conductive rails are used to support and guide one or more vehicles on the railway, and at the same time serve as a pair of parallel conductors for the alternating current supplied to the railway.
  • These rails emit a varying magnetic flux which is the medium by which power is transferred to the power collector, more particularly to a secondary winding within it.
  • These rails 11 are illustrated in Figure 1. Referring to Figure 1, the rails 11 are short-circuited at 12, and supplied by a power supply 13 providing alternating current.
  • the pick-up coil 14 of a trolley is connected via a series capacitor 15 to a rectifier 16 and a DC-DC converter 17 to supply a brushless DC motor 18.
  • the rails 11 are formed from a good electrical conductor such as aluminium, and this may be in the form of a solid or hollow section bar.
  • the preferred rails comprise hollow aluminium rails, of outside dimensions of 30mm x 30mm, having a central cavity, leaving a wall thickness of approximately 3mm on either side. This construction is suitable for lightweight trolleys or cars supported on the rail system.
  • the spacing of the rails is 600mm. Such a rail spacing is suitable for carts of approximately 800mm long x 600mm wide, as this dimension is relevant to the size of the coil which can be placed beneath the cart in close proximity to the rails.
  • the size of the coil and the frequency of the alternating current supplied to the rails enables the prototype unit to provide approximately 400 watts to an electric motor situated on the trolley.
  • the rails are preferably supported on non-electrically conductive material, in order to avoid shorting out the rails, or the dissipation of the inductive power into metallic components close to the rail.
  • the rails may be directly attached to an inert substrate, or may be supported or separated by insulated sleepers such as timber, or plastic sleepers.
  • insulated sleepers such as timber, or plastic sleepers.
  • the path of the railway is kept free of other metals, and in particular it is preferred that a space on either side of the rails, and above and below the rails equivalent to the rail spacing is substantially free of metal (other than the pick-up coil on the trolleys) in order to minimise inductive losses.
  • the wheels may be coated with, or made of, a plastics substance or another non-conductive material
  • the trolley 20 shown in Figure 2 preferably has a minimum of metal in close proximity to the powered rails, so that most of the power supplied by the rails is picked up by the coil 14 in close proximity to the rails, rather than by other metal components on the trolley. It is for this reason that the wheels 21 are preferably formed of a non- conductive material, such as a plastics material, although the axle 22 connecting the wheels may be a metal axle. As shown in Figure 2, the pair of wheels of the trolley (of which there would normally be four wheels) are connected by a solid axle, typically a metal axle 22 supported on a pair of bearings 24. The wheels themselves will normally be formed of a hardwearing plastics material, although in the prototype trolley the wheels were machined from a high density particle board.
  • the deck 26 of the trolley is preferably formed of wood or plastics, or another non- conductive material, and an electric motor 27 is positioned underneath the tray, preferably as far away from the rails as possible, and towards the centre of the tray, approximately equidistant from either rail.
  • Any convenient form of electric motor may be used, although in the prototype system, we prefer to use a brushless DC motor, with variable speed control.
  • the electric motor is preferably connected to the axle by means of a pair of pulleys 28, 29 connected by a belt (not shown).
  • the coil is preferably suspended beneath the trolley as close as possible to the rails although a clearance of 50 - 100 mm is acceptable.
  • a distance of 25mm has been allowed between the outer edges of the coil and the adjacent rail.
  • the wheels are preferably flanged wheels, and as is typical with railway systems the flanges are provided on the inside of the rail. This has worked satisfactorily in the prototype trolley, although if a closer coupling between the coil and the rail is desired, then an alternative wheel configuration may be used, for example, the wheels may be reversed so that the flanges sit on the outside of the rails, allowing the coils to be placed very close to the rails without the flanges intervening between the coils and rails. Other wheel and rail designs are possible.
  • the supply circuit 13 (see Figure 1) is preferably provided by means of a pulse width modulation integrated circuit such as a Texas Instruments TL494 chip.
  • the pick-up coil is approximately 600mm wide and 800mm long (corresponding as closely as possible to the overall dimensions of the trolley).
  • a 50-turn coil of 1mm copper wire resulting in an induced current of approximately 2 amps at 200 volts in the pick-up coil, providing approximately 400 watts to the motor.
  • the prototype coil is approximately 8mm wide and 10mm deep, made up of 50 x 1mm diameter insulated copper wires. This is shown as 14' in the circled expanded view in Figure 2.
  • the pick-up coil preferably forms part of a series resonant circuit, connected to a DC- DC converter to control the output from the coil so that it is suitable for driving a brushless DC motor.
  • the DC-DC converter may be of the buck converter type.
  • the frequency of the power supply to the rails will be fixed, although if desired, a variable frequency source could be used, particularly if additional demands are made on the system, eg if more heavily-laden trolleys are used at some times rather than others.
  • the system allows for one or more trolleys to be powered by the rails, and if desired each trolley can be independently controlled, so that its speed and location can be controlled by controlling the brushless DC motor on each trolley.
  • Intelligent controllers could be provided on each trolley to monitor the position of each trolley, and signals could be supplied via the rails to each trolley, and from each trolley to a central controller, if desired.
  • the series resonant circuit of Figure 5 is also shown schematically in Figure 1, and is connected to a rectifier, and to a DC-DC converter to provide speed control to a brushless DC motor.
  • This brushless DC motor is preferably connected to an axle directly coupled to a pair of wheels, so that if a trolley has four wheels, two will be driven, and the other pair will be allowed to free-wheel.
  • the invention allows the pick-up coil to be of a size close to the overall size of the trolley, ie the trolley will preferably be rectangular in plan view, as will the coil.
  • the coil can be close to the full width of the trolley. This construction has the advantage that no further wiring need be applied to the rail tracks.
  • EXAMPLE 2 • Figs 6a, 6b, 6c, 7a, 7b.
  • This embodiment describes an inductive power transfer system 60 adapted for use with a vehicle, specifically a small (20-seats) bus 70 used for a short route up and down a shopping street.
  • the vehicle or bus is planned to collect energy at charging stations 71 (usually identical to bus stops) along its route, where sources 62, 602, 76 of varying magnetic flux are provided, and store it for use as motive power between stops.
  • This vehicle and its inductive supply systems are optimised for simplicity rather than absolute efficiency.
  • This bus has a conventional arrangement of steerable rubber-tyred wheels at the front and a pair of driven rubber-tyred wheels 74 at the rear. It may be advantageous to have all four wheels steerable, to better serve particular applications.
  • the bus covers a road area of 7 metres in length, and 24 metres in width.
  • a power collector according to embodiments described earlier may be installed as a "skirt" around the perimeter of the bus (optionally curving up over wheel arches) and is provided as described in earlier embodiments with a series resonant capacitor of a size such that its reactance is substantially the same as the inductive reactance of the windings of the power collector.
  • the power collector may be inside the line of the wheels as shown by 77.
  • the calculations included herein relate to this example and clearly may be varied for different conditions - such as using a 117N AC, 60Hz supply.
  • Primary Loop or Coil 1000 A are provided in effect by a 9-turn primary loop, if the conductor current is 110 A.
  • Primary inductance L 2.4 x 1.2 x 9 2 ⁇ H/metre
  • Power factor correction using a capacitor across the input to the loop reduces the 110 A of circulating current to about 10 A of supply current.
  • the storage device is a relatively small number of deep-discharge lead-acid storage batteries 63 (although any other type of storage battery may be used).
  • the number of batteries preferred for any one vehicle is dependent on factors such as battery cost, durability (in terms of charge/discharge cycles) as against the feasible operating voltage, charging rate (and hence time), the distance between stops, battery weight and cost, and safety margins (such as a particular recharging stop being unavailable).
  • a suitable battery charger/battery monitor device is provided to rectify and optionally to change the voltage of the current from the power collector and charge the batteries whenever power is available, and to indicate the rate of charge and the state of charge.
  • Such devices are well known in the art.
  • the preferred electromotive transducer is a type of brushless DC motor, preferably of an ironless construction such as a "CADAC” motor, preferably having an output of about 30 KW, and preferably a single motor is coupled to the drive shaft of a conventional differential gearbox such as a two-speed "Eaton" differential.
  • CADAC CADAC
  • Each motor has its own controller to energise windings in the correct order, and usually this is driven by a variable DC supply derived from the battery voltage in order to provide a variable motor torque or speed.
  • Other types of motor may be preferred.
  • This vehicle design may have the usual features of electric motor drive such as regenerative braking, although the initial prototypes have deleted these features as the vehicle runs on a flat area in a not overly congested route.
  • a motor and its own controller
  • each wheel coupled through (for example) a planetary gearbox providing a geared-down ratio to the wheel hub.
  • a further alternative is the use of multiple pairs of drive wheels, each pair having its own motor and differential. The low speed of the differential may be required for extra driving torque.
  • Fig 6c An option intended to reduce track losses is the use of superconducting materials to carry the large currents.
  • 69 is an array of superconducting primary inductors 62c together with pipes for coolant 68 buried within insulation material 603 in a lined trench 602 under a roadway 601.
  • Newly developed superconducting materials based on copper oxide and yttrium are capable of exhibiting superconductivity at commercially realisable temperatures - above the boiling point of liquid nitrogen.
  • Each designated charging position would comprise for example a conventional kerbside bus stop 71.
  • a shallow channel 67b cut in a rectangular form into the roadway at a position which is intended to lie substantially beneath the power collector 77 of the stopped bus 70 is filled with loops of the primary conductor; preferably in the form of single-conductor, underground cable of the type comprising a single 12 mm diameter aluminium rod sheathed with double insulation and approved in New Zealand for use at up to 400V AC.
  • This type of insulated conductive cable has a relatively low ratio of external surface area to volume for the conductive portion, in contrast to multiconductor cables.
  • the length and number of turns are planned as outlined in the calculations above to provide a directly mains-connectable primary inductor, thereby discarding a transformer.
  • 65 is the mains input supply in Fig 6a, feeding through a controller 61 (including a power factor correction capacitor (as 19) and a contactor) and through wires 66 to the primary loops 62 (or 62b, or 76).
  • the power factor correction capacitor renders the primary loop a parallel resonant circuit carrying a circulating current about ten times larger (in one installation) than the injected current.
  • the primary conductor is preferably energised only when the correct type of vehicle is over the primary conductors.
  • Various indicators may be provided on the bus to indicate to the driver the best placement of the vehicle over the buried primary conductor - indicators such as a simple voltage or power meter, or external physical locators.
  • the ironless inductive power transfer system of the preferred embodiment works effectively with coil separation of the order of 100 mm (between 76 and 77 in Fig 7a) and, given a relatively stiff suspension for the bus and no humps in the roadway along the routes travelled, there may not be any need to provide means to physically lower the power collector support 78 into closer proximity with the roadway concealing the primary conductors. However this option may be used under other circumstances. Iron (preferably as laminations) may be used in proximity to either or both the primary conductors and the power collector in order to improve coupling, although it is believed that this is not cost-effective over more turns of cable, and may introduce other problems such as magnetic attractive forces and magnetostrictive acoustic signals and vibrations, as well as corrosion problems.
  • a microprocessor may be provided at each charging station to recognise a particular vehicle as one compatible with this system for inductive power transfer, to respond to a request for power, and then to energise the primary conductor (perhaps by closing a contactor) until such time as the vehicle moves off or signals that its batteries are charged.
  • Vehicle recognition may be visual (using number-plate image identification) or by means of radio or infra-red signalling 73.
  • Accounting may involve the use of a conventional telephone modem, a stored list of transactions read out directly at intervals, or a cellular telephone.
  • charging positions may be widely dispersed in the road environment (such as near traffic lights, etc) and vehicles capable of using the power then carry their own metering facilities.
  • This embodiment has the advantages over conventional trolley buses that it has no need for overhead wiring, no unreliable pantograph or other current collectors to the wiring, and can wait indefinitely or go anywhere within reason between charging stops.
  • a charging stop it has the advantage that functional connection is made without any purposive act by the driver - e.g. to plug in a connector to a fixed post, wait, then remove it. This is useful from safety and anti-vandal aspects as well.
  • the magnetic field emitted by the primary conductors 62, 76 is approximately 25% of the WHO recommendation for 50 Hz magnetic field intensity for human body exposure, and in any case is produced only when a suitable vehicle actually overlies the conductors.
  • a prototype rubber-tyred vehicle according to this embodiment having a power collector with a pickup coil of dimensions 1.2 x 2.4 metres; 100 turns and no on-board storage was capable of moving one person while consuming approximately 30 W of induced power within a "CADAC" brushless DC motor geared down by 40:1, and was still capable of driving against an obstacle (with consequent loss of traction) while consuming 800 W of transferred power.
  • the primary conductor loop comprised nine turns of cable as described previously, about 100 mm beneath the power collector coil, which was driven from an ordinary welding transformer fed from a 10A mains outlet with about 40 V AC, @ 50 Hz.
  • the overnight storage area and/or the entire route or portions of it may also be provided with primary conductors and energising means as described above.
  • the pick-up on the vehicle is preferably in the form of a series resonant circuit, it is possible to use a parallel resonant circuit, where lower power is required for the trolley. Although in most applications the power will be directed to an electric motor, it will be appreciated that the trolley may be provided with light sources, heating elements, or other "consumers" of electric power.
  • the rails can be formed from hollow metal sections, or if more solid rails are required, the rails could be formed of composite materials with only the outside few millimetres being formed of aluminium or other conductive material.

Abstract

This inductive power transfer system provides a capacitor (15), having a reactance equivalent to the inductive reactance of a pickup coil (14), in series between the windings of the pickup coil and the electrical load (16, 17, 18). A power-factor compensating capacitor (19) may be used at the feed to a loop one or a few turns of primary inductor cable (11, 12) so that a reasonable supply-mains current can maintain the primary inductor current. The length hence impedance of primary cable may be varied in order to match the primary inductor to the voltage of the supply mains. One described example is a mains-driven, iron-free, parallel-resonant primary and series-resonant secondary type of inductive power transfer system, capable of transferring about 5 kW of power to a 5 x 2.4 metre pickup coil under a vehicle (at 100 mm separation from the primary loop) at around 60 % efficiency. Energy storage in batteries (10) is optional. Another example uses conducting rails to carry power to a rail vehicle and hence induces commutator-less motive power in secondary windings.

Description

POWER COLLECTOR FOR INDUCTIVE POWER TRANSFER.
TECHNICAL FIELD OF THE INVENTION
This invention relates to a system for inductive transfer of power across a gap, useful in the provision of electric power to one or more mobile consumers of electric power. It has particular application to an electrically powered railway or to road vehicles.
BACKGROUND
The concept of inductive coupling as a roadway power transmission system has been known for approximately 100 years, and there have been many attempts to develop the use of inductive coupling for the transportation of road vehicles. However, they have not proved to be sufficiently efficient and hence not commercially successful.
OBJECT
It is an object of this invention to provide an improved induction system capable of powering vehicles, or one which will at least provide the public with a useful choice.
STATEMENT OF THE INVENTION.
In one aspect the invention comprises a power collector for collecting power from an inductive power transfer system across a space, using as its primary emitters of power as varying magnetic flux one or more primary conductors capable of carrying an alternating electric current having an operating frequency, the power collector comprising at least one capacitance and at least one coil of one or more windings for intercepting the magnetic field from the one or more primary conductors, and at least one electrical load, characterised in that the capacitance is in series with the coil and the load, and the reactance of the series capacitance is substantially equal to the inductive reactance of the coil at the operating frequency. In a subsidiary aspect the windings of the coil of the power collector are made of solid conductive metallic material.
In a further subsidiary aspect the electrical load comprises a device capable of immediately consuming the alternating current developed within the windings of the coil.
In an alternative subsidiary aspect the electrical load comprises a device capable of using power from a storage battery connected to the power collector.
In a yet further subsidiary aspect the load comprises a device capable of using the alternating current after a first conversion into direct current and a second conversion into a voltage or current of a regulated amplitude.
In a more direct subsidiary aspect the load comprises a DC motor capable of providing a motive power.
In a second main aspect the invention comprises a primary conductor (for use with a power collector), comprising an elongated loop formed from one or more turns of an insulated conductive cable of a type having, for the conductive portion, a low ratio of external surface area to volume.
In a related aspect the conductive cable may optionally comprise a superconductive material of a type capable of exhibiting a very low ohmic resistance when cooled to below its superconducting temperature.
In another aspect the invention provides an inductive power transfer system in combination with a power collector as previously described, said system comprising a source of alternating electric power having an operating frequency; a resonant primary; a vehicle having at least one said power collector mounted thereon; wherein said power collector comprises at least one capacitance and at least one coil of one or more windings for intercepting the magnetic field from the one or more primary conductors, and at least one electrical load, characterised in that the capacitance is in series with the coil and the load, and the reactance of the series capacitance is substantially equal to the inductive reactance of the coil at the operating frequency.
In another aspect at least one metallic rail may be used as a primary conductor, upon which a substantially non-conductive vehicle may be supported by at least one non- conductive support incapable of conducting an electric current from the rail.
In a further aspect the operating frequency of the source of alternating power used in this system lies in the range of from 30 Hz to 1 MHz.
More preferably the operating frequency of the source of alternating power is that of a local mains supply frequency or an integer multiple of the supply frequency.
In a yet further related aspect there is more than one, electrically separated, elongated and looped primary conductor; each loop being contiguous at at least one end with an adjacent loop.
Alternatively one or more physically separated primary loops are located at designated positions.
In a further aspect, the invention may comprise a self-powered vehicle, adapted for use with an inductive power transfer system, comprising at least three road wheels and means for control and guidance, at least one power collector, apparatus for conversion of electrical energy into a storable form, apparatus for storage of electrical energy, and apparatus for recovery of stored electrical energy and its controlled delivery to at least one electromotive transducer.
Other subsidiary aspects will become apparent from the claims and the text of this specification.
DRAWINGS
These and other aspects of the invention, which should be considered in all its novel aspects, will become apparent from the following description, which is given by way of example only, with reference to the accompanying drawings, in which: FIG. 1 is a schematic diagram of an inductively coupled railway with series capacitor.
FIG. 2 illustrates a cross-section through a pair of rails, and through an electrically powered trolley positioned on said rails.
FIG. 3 is a top plan view of a coil positioned above said pair of rails.
FIG. 4 illustrates a simple resonant circuit to illustrate the power pick-up in the coil of the vehicle.
FIG. 5 illustrates a series resonant circuit for use in the coil of this invention.
FIG. 6a illustrates a vehicle with on-board storage at a designated charging place.
FIG. 6b illustrates a preferred primary conductor loop.
FIG. 6c illustrates a superconducting primary conductor loop.
FIG. 7a illustrates a vehicle at a designated charging place, illustrating the relationship of the primary windings and the power collector.
FIG. 7b illustrates a section through a power collector.
EXAMPLE 1
Alternating current is supplied to a pair of parallel conductors (in this case a pair of electrically conductive rails 11). The frequency may vary from about 50 Hertz (50 Hz) to several MegaHertz (MHz) depending upon the size and nature of the track and trolley, and the relative economics of high frequency generation over frequencies related to mains frequencies.
Preferably the power is supplied at a frequency in the range of 2 KiloHertz (KHz) to 20
KHz. The prototype described in the preferred embodiment, and in the calculations, made use of a power supply of 10 KHz. The frequency and the current developed by the power supply may be selected, or varied, depending upon the size and nature of the rails, the size and nature of the pick-up coil, and the power requirements of the electric motor or motors on each trolley.
The induction system of this invention is particularly suited to an electrical railway in which a pair of electrically conductive rails are used to support and guide one or more vehicles on the railway, and at the same time serve as a pair of parallel conductors for the alternating current supplied to the railway. These rails emit a varying magnetic flux which is the medium by which power is transferred to the power collector, more particularly to a secondary winding within it. These rails 11 are illustrated in Figure 1. Referring to Figure 1, the rails 11 are short-circuited at 12, and supplied by a power supply 13 providing alternating current. The pick-up coil 14 of a trolley is connected via a series capacitor 15 to a rectifier 16 and a DC-DC converter 17 to supply a brushless DC motor 18.
As shown in Figure 2, it is preferred that the rails 11 are formed from a good electrical conductor such as aluminium, and this may be in the form of a solid or hollow section bar. In a prototype of this invention, the preferred rails comprise hollow aluminium rails, of outside dimensions of 30mm x 30mm, having a central cavity, leaving a wall thickness of approximately 3mm on either side. This construction is suitable for lightweight trolleys or cars supported on the rail system. In this prototype, the spacing of the rails is 600mm. Such a rail spacing is suitable for carts of approximately 800mm long x 600mm wide, as this dimension is relevant to the size of the coil which can be placed beneath the cart in close proximity to the rails.
As will become apparent from the calculations in the example, the size of the coil and the frequency of the alternating current supplied to the rails enables the prototype unit to provide approximately 400 watts to an electric motor situated on the trolley.
The rails are preferably supported on non-electrically conductive material, in order to avoid shorting out the rails, or the dissipation of the inductive power into metallic components close to the rail. For example, the rails may be directly attached to an inert substrate, or may be supported or separated by insulated sleepers such as timber, or plastic sleepers. In designing an inductively powered railway, it is preferred that the path of the railway is kept free of other metals, and in particular it is preferred that a space on either side of the rails, and above and below the rails equivalent to the rail spacing is substantially free of metal (other than the pick-up coil on the trolleys) in order to minimise inductive losses. As there is no direct electrical contact between the wheels and the rails, it is possible to coat the surface of the rails with an insulating or protective coating, such a coating may reduce transport noise in the system.
Alternatively, the wheels may be coated with, or made of, a plastics substance or another non-conductive material
The trolley 20 shown in Figure 2 preferably has a minimum of metal in close proximity to the powered rails, so that most of the power supplied by the rails is picked up by the coil 14 in close proximity to the rails, rather than by other metal components on the trolley. It is for this reason that the wheels 21 are preferably formed of a non- conductive material, such as a plastics material, although the axle 22 connecting the wheels may be a metal axle. As shown in Figure 2, the pair of wheels of the trolley (of which there would normally be four wheels) are connected by a solid axle, typically a metal axle 22 supported on a pair of bearings 24. The wheels themselves will normally be formed of a hardwearing plastics material, although in the prototype trolley the wheels were machined from a high density particle board.
The deck 26 of the trolley is preferably formed of wood or plastics, or another non- conductive material, and an electric motor 27 is positioned underneath the tray, preferably as far away from the rails as possible, and towards the centre of the tray, approximately equidistant from either rail. Any convenient form of electric motor may be used, although in the prototype system, we prefer to use a brushless DC motor, with variable speed control. The electric motor is preferably connected to the axle by means of a pair of pulleys 28, 29 connected by a belt (not shown).
The coil is preferably suspended beneath the trolley as close as possible to the rails although a clearance of 50 - 100 mm is acceptable. In the prototype a distance of 25mm has been allowed between the outer edges of the coil and the adjacent rail. As shown in Figure 2 the wheels are preferably flanged wheels, and as is typical with railway systems the flanges are provided on the inside of the rail. This has worked satisfactorily in the prototype trolley, although if a closer coupling between the coil and the rail is desired, then an alternative wheel configuration may be used, for example, the wheels may be reversed so that the flanges sit on the outside of the rails, allowing the coils to be placed very close to the rails without the flanges intervening between the coils and rails. Other wheel and rail designs are possible.
In the prototype, we have used a power supply capable of supplying an alternating current of 10 KHz, at 100 amperes. The supply circuit 13 (see Figure 1) is preferably provided by means of a pulse width modulation integrated circuit such as a Texas Instruments TL494 chip.
The pick-up coil is approximately 600mm wide and 800mm long (corresponding as closely as possible to the overall dimensions of the trolley). In the prototype we have used a 50-turn coil of 1mm copper wire resulting in an induced current of approximately 2 amps at 200 volts in the pick-up coil, providing approximately 400 watts to the motor.
In cross-section the prototype coil is approximately 8mm wide and 10mm deep, made up of 50 x 1mm diameter insulated copper wires. This is shown as 14' in the circled expanded view in Figure 2.
The pick-up coil preferably forms part of a series resonant circuit, connected to a DC- DC converter to control the output from the coil so that it is suitable for driving a brushless DC motor. The DC-DC converter may be of the buck converter type.
In most cases the frequency of the power supply to the rails will be fixed, although if desired, a variable frequency source could be used, particularly if additional demands are made on the system, eg if more heavily-laden trolleys are used at some times rather than others.
The system allows for one or more trolleys to be powered by the rails, and if desired each trolley can be independently controlled, so that its speed and location can be controlled by controlling the brushless DC motor on each trolley. Intelligent controllers could be provided on each trolley to monitor the position of each trolley, and signals could be supplied via the rails to each trolley, and from each trolley to a central controller, if desired.
The series resonant circuit of Figure 5 is also shown schematically in Figure 1, and is connected to a rectifier, and to a DC-DC converter to provide speed control to a brushless DC motor. This brushless DC motor is preferably connected to an axle directly coupled to a pair of wheels, so that if a trolley has four wheels, two will be driven, and the other pair will be allowed to free-wheel.
In its preferred form the invention allows the pick-up coil to be of a size close to the overall size of the trolley, ie the trolley will preferably be rectangular in plan view, as will the coil. By using the rails as conductors, the coil can be close to the full width of the trolley. This construction has the advantage that no further wiring need be applied to the rail tracks.
CALCULATIONS for EXAMPLE 1 -
In the following example reference is made to the parallel rail shown in Figure 1, and to the schematic diagrams shown in Figure 3, 4 and 5. In the following calculations reference will be made to a pair of rails (parallel conductors) at a spacing of 1 metre between them, for ease of demonstration.
Taking 2 parallel conductors at a spacing of 1 metre between them, then they have an inductance L = 1.2 microhenries/metre.
If a rectangular coil of wire is placed close to the parallel wire, as in Figure 3, a movable transformer is created where the stationery parallel wires are the primary winding and the secondary winding is the coil of wire of N turns, with length / metres.
Therefore the area of mutual inductance between the primary and secondary remains constant as the secondary is moved along the length of the primary winding.
For simplicity let N = 1 and / = 1 metre, then we have a secondary winding of 1.2 microhenries.
Now if the frequency of the supply is, say 10 KHz, and it is applied to one end of the primary winding and the other end shorted, then the following equations apply:
Z^ = jπ x 1.2 x 10"6 x / ZL = impedance in ohms let / p = 10 metres / p = leng βth in metres •= j2π x 104 x 1.2 x 10"6 x 10 ω = 2πf
ZL = j0.754 ohms f = 10 KHz
Now if a current of 100 amperes is passed through the primary section, then a voltage of 75.4 volts will occur across the input. This corresponds to 7.54 volts/metre and therefore by mutual inductance 7.54 volts will appear across the 1 turn secondary winding.
Now if the secondary winding is loaded as shown in Figure 4, the impedance will limit the output voltage and therefore output power as follows:
Figure imgf000011_0001
to obtain maximum power transfer R = 7^ (see Figure 4).
Power P = V x l
= V γs x V vs
2 2 x R
= VV vvss22
2R
To increase the power transfer a series resonant capacitor can be placed in the circuit as shown in Figure 5.
If jZL = -jZc then the output impedance will be zero but current limiting occurs due to the impedance of the remaining uncovered section of the primary.
Therefore by transformer action maximum current in the secondary will be 100 amperes (if 100% coupling occurs). Therefore maximum output power occurs
when R = jZL = -jZc and Power P = Vs 2 which is double the previous maximum output power possible without resonance.
In the example given then the maximum power P = 7.542 = 754 watts
0.0754
The increase of resistance due to "skin effect" should also be taken into account. An aluminium conductor of 3mm diameter will have a 10% increase in resistance at 10 KHz. Therefore care must be taken in calculating the actual resistance of conductors used. In one experiment, a 12mm by 12mm aluminium busbar was used as a combined rail and primary conductor for a powered rail system.
This gave a measured AC resistance of 14 milliohms for a 10 metre section and losses of 200 watts at a current of 100 amperes.
EXAMPLE 2 • Figs 6a, 6b, 6c, 7a, 7b. This embodiment describes an inductive power transfer system 60 adapted for use with a vehicle, specifically a small (20-seats) bus 70 used for a short route up and down a shopping street. The vehicle or bus is planned to collect energy at charging stations 71 (usually identical to bus stops) along its route, where sources 62, 602, 76 of varying magnetic flux are provided, and store it for use as motive power between stops. This vehicle and its inductive supply systems are optimised for simplicity rather than absolute efficiency.
This bus has a conventional arrangement of steerable rubber-tyred wheels at the front and a pair of driven rubber-tyred wheels 74 at the rear. It may be advantageous to have all four wheels steerable, to better serve particular applications.
The bus covers a road area of 7 metres in length, and 24 metres in width. A power collector according to embodiments described earlier may be installed as a "skirt" around the perimeter of the bus (optionally curving up over wheel arches) and is provided as described in earlier embodiments with a series resonant capacitor of a size such that its reactance is substantially the same as the inductive reactance of the windings of the power collector. Alternatively the power collector may be inside the line of the wheels as shown by 77. The calculations included herein relate to this example and clearly may be varied for different conditions - such as using a 117N AC, 60Hz supply.
CALCULATIONS for EXAMPLE 2 -
Power Collector: Coil dimensions: 5 m length x 2.4 m, rectangular. Wire: 100 turns of 2.0 mm copper. Coil res. Rc = 100 x 15m / 15 x π x 4
= 8 ohms Coil inductance = 1.2 x 104 x 2.4 x 5 μH =144 mH (millihenries)
Coil impedance @50Hz = 144x50x2xπx 10'3 ohms
= 45 ohms Series capacitance = 45 ohms Coil Voltage = turns ratio x coupling ratio x 8 V/m x length = 100/9 x 0.9 x 8 x 5
= 400VAC
(This voltage depends on the number of turns used and may be altered according to requirements.)
As the coil resistance is 8 ohms, then maximum power transfer occurs when V out = 1/2 V open circuit
I ou „t = 200/8 = 25 A P ou ,t =25Ax400V
= 5 Kw @ η = 50%
Normally, to keep efficiency higher, the current may be limited to 10 A, whereupon the output power from the collector =400- (10x8)
= 320 VAC P ou ,t =3.2KW.
Primary Loop or Coil: 1000 A are provided in effect by a 9-turn primary loop, if the conductor current is 110 A. Primary inductance L = 2.4 x 1.2 x 92 μH/metre
= 233 μH/metre At 110 A the voltage per metre V =233xωxll0Axl0-°
(where ω (omega) = 2 x π x 50) V = 8V/metre
Therefore a 30 metre track could be run directly off a 240 V AC mains supply. (30x8 =240)
Power factor correction using a capacitor across the input to the loop reduces the 110 A of circulating current to about 10 A of supply current.
ZL = 240/110
= 2.2 ohms
ZC=ZL = l/ωC
C = ll/(ωx2.2)
C = 1450 μF (microfarads).
Track losses (I2R) , assuming 95 mm2 aluminium rod as the primary conductor, are: PL =1102x(9x2)/(36x 95)
= 64 W per metre, or 1920 W for a 30 metre track. Up to three 10 metre long buses could be charged at one time. For only one bus, the total losses are:
PL = 1.92 Kw + 4 Kw
Power out P0 =3.2Kw
System efficiency η % = 3.2/4.92 = 65%
The storage device is a relatively small number of deep-discharge lead-acid storage batteries 63 (although any other type of storage battery may be used). The number of batteries preferred for any one vehicle is dependent on factors such as battery cost, durability (in terms of charge/discharge cycles) as against the feasible operating voltage, charging rate (and hence time), the distance between stops, battery weight and cost, and safety margins (such as a particular recharging stop being unavailable).
A suitable battery charger/battery monitor device is provided to rectify and optionally to change the voltage of the current from the power collector and charge the batteries whenever power is available, and to indicate the rate of charge and the state of charge. Such devices are well known in the art.
The preferred electromotive transducer is a type of brushless DC motor, preferably of an ironless construction such as a "CADAC" motor, preferably having an output of about 30 KW, and preferably a single motor is coupled to the drive shaft of a conventional differential gearbox such as a two-speed "Eaton" differential. Each motor has its own controller to energise windings in the correct order, and usually this is driven by a variable DC supply derived from the battery voltage in order to provide a variable motor torque or speed. Other types of motor may be preferred.
This vehicle design may have the usual features of electric motor drive such as regenerative braking, although the initial prototypes have deleted these features as the vehicle runs on a flat area in a not overly congested route.
Alternatively a motor (and its own controller) could separately drive each wheel, coupled through (for example) a planetary gearbox providing a geared-down ratio to the wheel hub. A further alternative is the use of multiple pairs of drive wheels, each pair having its own motor and differential. The low speed of the differential may be required for extra driving torque.
An option intended to reduce track losses is the use of superconducting materials to carry the large currents. Such an arrangement is illustrated in Fig 6c, where 69 is an array of superconducting primary inductors 62c together with pipes for coolant 68 buried within insulation material 603 in a lined trench 602 under a roadway 601. Newly developed superconducting materials based on copper oxide and yttrium (for example) are capable of exhibiting superconductivity at commercially realisable temperatures - above the boiling point of liquid nitrogen.
Each designated charging position would comprise for example a conventional kerbside bus stop 71. A shallow channel 67b cut in a rectangular form into the roadway at a position which is intended to lie substantially beneath the power collector 77 of the stopped bus 70 is filled with loops of the primary conductor; preferably in the form of single-conductor, underground cable of the type comprising a single 12 mm diameter aluminium rod sheathed with double insulation and approved in New Zealand for use at up to 400V AC. This type of insulated conductive cable has a relatively low ratio of external surface area to volume for the conductive portion, in contrast to multiconductor cables. Preferably the length and number of turns are planned as outlined in the calculations above to provide a directly mains-connectable primary inductor, thereby discarding a transformer. 65 is the mains input supply in Fig 6a, feeding through a controller 61 (including a power factor correction capacitor (as 19) and a contactor) and through wires 66 to the primary loops 62 (or 62b, or 76). In effect, the power factor correction capacitor renders the primary loop a parallel resonant circuit carrying a circulating current about ten times larger (in one installation) than the injected current. Alternative installations may use frequency-doubling techniques or otherwise raise the frequency of the primary alternating current, as the coupling is improved by the square of the operating frequency, but it is believed that the economic cost and costs in terms of reliability of such improvements are greater than using more turns of cable (now at NZ $2.50 per metre).
In order to minimise wasted power, the primary conductor is preferably energised only when the correct type of vehicle is over the primary conductors. Various indicators may be provided on the bus to indicate to the driver the best placement of the vehicle over the buried primary conductor - indicators such as a simple voltage or power meter, or external physical locators.
The ironless inductive power transfer system of the preferred embodiment works effectively with coil separation of the order of 100 mm (between 76 and 77 in Fig 7a) and, given a relatively stiff suspension for the bus and no humps in the roadway along the routes travelled, there may not be any need to provide means to physically lower the power collector support 78 into closer proximity with the roadway concealing the primary conductors. However this option may be used under other circumstances. Iron (preferably as laminations) may be used in proximity to either or both the primary conductors and the power collector in order to improve coupling, although it is believed that this is not cost-effective over more turns of cable, and may introduce other problems such as magnetic attractive forces and magnetostrictive acoustic signals and vibrations, as well as corrosion problems.
In the present embodiment the only consumers are part of one organisation, but if multiple groups of consumers were to use the power some means to charge for the power taken may be required. In order to cater for that possibility, a microprocessor may be provided at each charging station to recognise a particular vehicle as one compatible with this system for inductive power transfer, to respond to a request for power, and then to energise the primary conductor (perhaps by closing a contactor) until such time as the vehicle moves off or signals that its batteries are charged. Vehicle recognition may be visual (using number-plate image identification) or by means of radio or infra-red signalling 73. Accounting may involve the use of a conventional telephone modem, a stored list of transactions read out directly at intervals, or a cellular telephone. Alternatively charging positions may be widely dispersed in the road environment (such as near traffic lights, etc) and vehicles capable of using the power then carry their own metering facilities.
This embodiment has the advantages over conventional trolley buses that it has no need for overhead wiring, no unreliable pantograph or other current collectors to the wiring, and can wait indefinitely or go anywhere within reason between charging stops. At a charging stop it has the advantage that functional connection is made without any purposive act by the driver - e.g. to plug in a connector to a fixed post, wait, then remove it. This is useful from safety and anti-vandal aspects as well.
The magnetic field emitted by the primary conductors 62, 76 is approximately 25% of the WHO recommendation for 50 Hz magnetic field intensity for human body exposure, and in any case is produced only when a suitable vehicle actually overlies the conductors.
A prototype rubber-tyred vehicle according to this embodiment, having a power collector with a pickup coil of dimensions 1.2 x 2.4 metres; 100 turns and no on-board storage was capable of moving one person while consuming approximately 30 W of induced power within a "CADAC" brushless DC motor geared down by 40:1, and was still capable of driving against an obstacle (with consequent loss of traction) while consuming 800 W of transferred power. The primary conductor loop comprised nine turns of cable as described previously, about 100 mm beneath the power collector coil, which was driven from an ordinary welding transformer fed from a 10A mains outlet with about 40 V AC, @ 50 Hz.
In a variation the overnight storage area, and/or the entire route or portions of it may also be provided with primary conductors and energising means as described above.
VARIATIONS
Although the pick-up on the vehicle is preferably in the form of a series resonant circuit, it is possible to use a parallel resonant circuit, where lower power is required for the trolley. Although in most applications the power will be directed to an electric motor, it will be appreciated that the trolley may be provided with light sources, heating elements, or other "consumers" of electric power.
Although the arrangement in Figure 2 shows the coil mounted beneath the tray of the trolley, in-board of the rails, it will be apparent that an alternative allows the coil to be slightly wider than the rail spacing, with the coil situated on the outside perimeter of the trolley, at a height just above that of the rails, so that the coil extends across the outside front and rear of the trolley perimeter, and extends on the outside of the wheels, to provide an even closer coupling between the coil and the rails. Such an arrangement would approximate to the coil shown in Figure 2, which is wider than the rail spacing.
Because of the importance of the skin effect at higher frequencies, the rails can be formed from hollow metal sections, or if more solid rails are required, the rails could be formed of composite materials with only the outside few millimetres being formed of aluminium or other conductive material.
Finally, it will be appreciated that various alterations or modifications may be made to the foregoing without departing from the scope of this invention as set forth in the following claims.

Claims

1. A power collector for collecting power from an inductive power transfer system across a space, using as its primary emitters of varying magnetic flux one or more primary conductors capable of carrying an alternating electric current having an operating frequency, the power collector comprising at least one capacitance and at least one coil of one or more windings for intercepting the magnetic field from the one or more primary conductors, and at least one electrical load, characterised in that the capacitance is in series with the coil and the load, and the reactance of the series capacitance is substantially equal to the inductive reactance of the coil at the operating frequency.
2. A power collector as claimed in claim 1, characterised in that the windings of the coil of the power collector are made of solid conductive metallic material.
3. A power collector as claimed in claim 1, characterised in that the electrical load comprises a device capable of immediately consuming the alternating current developed within the windings of the coil.
4. A power collector as claimed in claim 1, in which the load comprises a device capable of using power from a storage battery connected to the power collector.
5. A power collector as claimed in claim 1, characterised in that the load comprises a device capable of using the alternating current after a first conversion into direct current and a second conversion into a voltage or current of a regulated amplitude.
6. A power collector as claimed in claim 1, characterised in that the load comprises a DC motor capable of providing a motive power.
7. A primary conductor for use with a power collector as claimed in claim 1, characterised in that the primary conductor is an elongated loop formed from one or more turns of an insulated conductive cable of a type having, for the conductive portion, a low ratio of external surface area to volume.
8. A primary conductor as claimed in claim 7, characterised in that the conductive cable comprises a superconductive material of a type capable of exhibiting a very low ohmic resistance when cooled to below its superconducting temperature.
9. An inductive power transfer system in combination with a power collector as claimed in claim 1, said system comprising a source of alternating electric power having an operating frequency; a resonant primary; a vehicle having at least one said power collector mounted thereon; wherein said power collector comprises at least one capacitance and at least one coil of one or more windings for intercepting the magnetic field from the one or more primary conductors, and at least one electrical load, characterised in that the capacitance is in series with the coil and the load, and the reactance of the series capacitance is substantially equal to the inductive reactance of the coil at the operating frequency.
10. An inductive power transfer system as claimed in claim 9, characterised in that the operating frequency of the source of alternating power lies in the range of from 30 Hz to 1 MHz.
11. An inductive power transfer system as claimed in claim 9, characterised in that the operating frequency of the source of alternating power is that of a local mains supply frequency or to an integer multiple of the supply frequency.
12. An inductive power transfer system as in claim 9, characterised in that there is more than one, electrically separated, elongated and looped primary conductor; each loop being contiguous at at least one end with an adjacent loop.
13. An inductive power transfer system as claimed in claim 9, characterised in that said resonant primary comprises one or more physically separated loops which are located at designated positions so that the power collector is energised when said vehicle is in physical proximity to any one of said loops.
14. A self-powered vehicle, adapted for use with an inductive power transfer system as claimed in any previous claim, comprising at least three road wheels and means for control and guidance, characterised in that it includes at least one power collector as claimed in claim 1, apparatus for conversion of electrical energy into a storable form, apparatus for storage of electrical energy, and apparatus for recovery of stored electrical energy and its controlled delivery to at least one electromotive transducer.
PCT/NZ1993/000030 1993-05-03 1993-05-03 Power collector for inductive power transfer WO1994025304A1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
PCT/NZ1993/000030 WO1994025304A1 (en) 1993-05-03 1993-05-03 Power collector for inductive power transfer
US08/545,723 US5839554A (en) 1993-05-03 1993-05-03 Power collector for inductive power transfer
AU40933/93A AU4093393A (en) 1993-05-03 1993-05-03 Power collector for inductive power transfer

Applications Claiming Priority (1)

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PCT/NZ1993/000030 WO1994025304A1 (en) 1993-05-03 1993-05-03 Power collector for inductive power transfer

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